Comprehensive Analysis of Pressure Sensor and Transmitter Performance Parameters: Selection, Installation, and Application Guide

In the fields of industrial automation, process control, and equipment monitoring, pressure measurement is almost ubiquitous. From hydraulic systems to chemical reactors, from water treatment to pharmaceutical production lines, accurate and reliable pressure data directly affects production safety, product quality, and energy efficiency. As the core sensing element, the performance parameters of a pressure sensor determine the credibility of the entire measurement system. A pressure transmitter converts these parameters into standard signals, making integration with control systems convenient.

Performance parameters and selection guidelines summarized by professional institutions such as Nanjing Hangjia Technology provide valuable references for engineers. Based on these classic materials and combined with the actual characteristics of the Nexisense pressure transmitter series, this article systematically reviews key performance indicators of pressure sensors, correct selection methods, installation essentials, and daily maintenance recommendations, helping you make wiser choices under complex operating conditions.

Core Performance Parameters of Pressure Sensors

Understanding the performance parameters of pressure sensors is the first step in selection. These parameters directly determine sensor performance and service life in real environments.

Rated Pressure Range

The rated pressure range refers to the pressure interval within which the sensor’s output characteristics meet the manufacturer’s specified accuracy and linearity requirements. It is usually marked as 0–X MPa or -1–Y bar. In practical applications, the measured pressure should always remain within this range to ensure measurement accuracy and long-term stability.

Many Nexisense models adopt wide-range designs, such as 0–10 MPa general-purpose types, while also providing higher overload capacity, giving users more margin during selection.

Maximum Pressure Range (Overload Pressure)

The maximum pressure range refers to the pressure value that the sensor can withstand for a long time without permanent output drift or characteristic changes. For semiconductor piezoresistive sensors, to optimize linearity and temperature performance, the rated range is often intentionally reduced; therefore, the maximum pressure is usually 2–3 times the rated pressure, or even higher.

This parameter is particularly important in systems with pulsating pressure or water hammer effects. It is recommended to leave at least a 1.5× safety margin during selection.

Burst Pressure (Destructive Pressure)

Burst pressure is the ultimate value that causes permanent damage to the sensor diaphragm, housing, or internal structure, and is usually far higher than the maximum pressure range. Nexisense products undergo strict testing for this indicator, with typical burst pressures reaching 3–5 times the rated pressure, providing extra protection for extreme operating conditions.

Linearity

Linearity describes the deviation between the sensor output signal and a straight line relative to the input pressure, expressed as a percentage of full scale (e.g., ±0.25%FS). The better the linearity, the closer the measurement result is to the true value, especially when using the full range.

Modern diffused silicon sensors, through laser trimming and digital compensation, can control linearity within ±0.1%FS. Nexisense high-end series adopts such technologies.

Pressure Hysteresis

Pressure hysteresis reflects the difference in output value at the same pressure point during increasing and decreasing pressure processes, usually expressed as a percentage of full scale (e.g., ±0.1%FS). Sensors with low hysteresis are more suitable for applications requiring high repeatability, such as precision hydraulic control.

Temperature Range and Compensation Performance

Temperature has a significant impact on pressure sensors, mainly divided into:

• Operating temperature range: the temperature range in which the sensor can operate normally, though accuracy may decrease.

• Compensated temperature range: the temperature range in which accuracy remains within specified error limits through temperature compensation circuits.

Nexisense products widely adopt full-temperature compensation technology, with compensation ranges typically covering -20°C to 80°C. Some high-temperature models can be extended to -40°C to 150°C, effectively reducing temperature drift.

Other important parameters include zero temperature drift, sensitivity temperature coefficient, repeatability, long-term stability, vibration resistance level, and protection rating (IP67/IP68). Together, these form a comprehensive performance profile of the sensor.

Key Points for Correct Pressure Transmitter Selection

Pressure transmitter selection involves far more than just range and accuracy; process, medium, and environmental factors must also be comprehensively considered.

Reasonable Matching of Range and Accuracy

For static or slowly changing pressure, it is recommended that the measured pressure accounts for about 2/3 of the full scale. For pulsating pressure, about 1/2 of full scale is recommended to balance resolution and overload capability.

Common accuracy classes include 0.1%, 0.25%, and 0.5%. Nexisense offers multiple accuracy options from 0.1% to 0.5%FS, allowing users to flexibly choose based on cost-effectiveness and process requirements.

Characteristics of the Measured Medium

The corrosiveness, viscosity, crystallization tendency, temperature, and presence of solid particles in the medium directly determine whether special materials or structures are required.

• Corrosive media: select 316L, Hastelloy, or tantalum diaphragms.

• High viscosity or crystallizing media: diaphragm seal or flange-type structures are recommended.

• High-temperature media: select cooling bends or capillary heat-dissipation types.

• Special gases such as oxygen or acetylene: oil-free dedicated instruments must be used.

The Nexisense diaphragm pressure transmitter series is optimized for corrosive and high-viscosity media, with multiple corrosion-resistant alloy diaphragm materials available.

Adaptability to On-Site Environment

Environmental factors such as vibration, humidity, strong electromagnetic interference, and extreme temperatures cannot be ignored.

• Vibration environments: select models with vibration-damping structures or silicone oil filling.

• Moist or submerged environments: protection rating IP67 or higher.

• Hazardous areas: select products certified with Ex d or Ex ia.

Installation and Observation Convenience

Select dial size (100 mm, 150 mm, etc.) and installation method (radial, axial) according to site conditions. For remote transmission, prioritize standard outputs such as 4–20 mA, HART, or Modbus RTU.

Key Considerations in Installation and Use

Even with correct selection, improper installation can introduce system errors. The following points have been repeatedly verified in engineering practice.

Pressure Tapping Point Selection

Avoid elbows, branches, and turbulent areas. The tapping distance before a control valve should be ≥2 times the pipe diameter, and ≥3 times after the valve. For vessels, tapping points should be located in areas with stable fluid flow.

Impulse Line Routing Principles

Maintain appropriate slopes to facilitate venting or drainage. For gas media, impulse lines should slope downward toward the tapping point; for liquid media, slope downward toward the instrument. Install drain valves or condensers when necessary.

Rational Configuration of Auxiliary Devices

• Corrosive or viscous media: install isolation devices.

• Pulsation or water hammer: install snubbers or dampers.

• High-temperature media: install cooling coils or capillaries.

• Severe vibration: install vibration pads or fixed brackets.

Basic Usage Specifications

Install instruments vertically; minimize impulse line length; ensure no leakage; new instruments must be verified before installation; instruments in long-term use are recommended to be calibrated once a year.

FAQ

1. What is the difference between rated pressure range and maximum pressure range?
          The rated range is the operating interval that guarantees accuracy and linearity, while the maximum pressure range is the overload limit that can be withstood long-term, possibly at the expense of some accuracy.

2. What practical impact does poor linearity have?
          Poor linearity causes systematic deviations at different pressure ranges, especially noticeable when using the full scale.

3. Are temperature compensation range and compensated temperature range the same?
          They usually refer to the same concept: the temperature range in which temperature drift is controlled within specified errors through compensation circuits.

4. How do you determine whether an isolation device is needed?
          When the medium is highly corrosive, highly viscous, prone to crystallization, or contains solid particles, a diaphragm seal should be installed to protect the sensor.

5. How should selection be done under pulsating pressure conditions?
          Prioritize models with adjustable damping or built-in snubbers, and leave a larger margin when selecting the range (measured value about 1/2 of full scale).

6. Which communication protocols do Nexisense pressure transmitters support?
          Mainstream models support 4–20 mA + HART and RS485 Modbus RTU; some high-end models support PROFIBUS PA or Foundation Fieldbus.

7. How often should a pressure transmitter be calibrated?
          Generally once a year; for critical equipment or highly corrosive environments, this can be shortened to six months, depending on usage conditions and metrology requirements.

8. Must explosion-proof transmitters be used in hazardous areas?
          Yes. Products with appropriate explosion-proof certification (e.g., Ex d IIC T6 Gb or Ex ia IIC T4 Ga) must be used and installed by qualified personnel.

9. Does an excessively long impulse line affect measurement?
          Yes. Overly long impulse lines increase pressure transmission delay and temperature error. It is recommended to keep them within 5 meters, or use larger diameters or special compensation measures if necessary.

10. What must be done before installing a newly purchased pressure transmitter?
           Visual inspection, insulation testing, and verification or calibration by a qualified metrology institution are required to ensure factory accuracy.

Conclusion

The performance parameters of pressure sensors and transmitters are not isolated numbers, but an integrated system closely coupled with actual operating conditions. Only by correctly understanding rated range, overload capacity, linearity, hysteresis, and temperature characteristics, and selecting products based on medium properties, environmental conditions, and process requirements, can the true potential of the equipment be realized.

The Nexisense pressure transmitter series, with high stability, wide adaptability, and reliable protection design, helps users achieve precise measurement and stable control in power generation, chemical processing, water treatment, pharmaceuticals, and many other fields. Choosing the right product, installing it in the right location, and using it correctly are the foundations of long-term reliable pressure measurement systems.

We hope this article provides practical reference value. If you are seeking a suitable pressure measurement solution for a specific project, you are welcome to further discuss your operating conditions with us. We look forward to providing more targeted technical support.